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CERN Accelerator School
Power converter requirements

2
Jean-Paul Burnet
CERN
CAS, Baden, 7-14 May 2014
Introduction
What do we power?
What is special with magnet powering?
What are the power converter requirements?
Magnet parameters
Circuit layout
Operation duty cycles
Power converter performance
What shall contain a functional specification?
What should I worry about?

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Introduction
This talk will describe the beginning of a project for a new particles accelerator.

Before any design of power converters, the first step is to write a functional specification
which describes the powering of the accelerator and the performance required by the
power converters.

Many technical points have to be raised and worked for optimization.

4
ELENA: Extra Low Energy Antiproton Ring
Introduction
Wikipedia: A power supply is a device that supplies electric power to an electrical load.

5
Power supplies are everywhere:
Computer, electronics, motor drives,

Here, the presentation covers only the
very special ones for particles
accelerators.

Power supply # power converter
US labs use magnet power supplies
CERN accelerators use power converter
CERN experiments use power supply

What do we power?
The main loads of a particles accelerator are the magnets and the radiofrequency system.
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What do we power?
The magnet families are :

Dipole: Bend the beam

Quadrupole: focus the beam

Sextupole: correct chromaticity

Octupole: Landau damping

Skew: coupling horizontal&vertical betatron oscillations
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http://cas.web.cern.ch/CAS/Belgium-2009/Lectures/Bruges-lectures.htm
What do we power?
For beam transfer, special magnets are needed. The families are :

Electrostatic septum

Septum magnet

Kicker Magnet
Rise time # 10ns-1s

Kicker generators are very special and generally handled by kicker people.
8
http://cas.web.cern.ch/CAS/Belgium-2009/Lectures/Bruges-lectures.htm

What do we power?
For the radio frequency system, the RF power comes through power amplifiers.
The families of RF power amplifiers are :

Solid state amplifier, Low power, 100V, 1100kW

Tetrode, Medium power, 10kV, 100kW

IOT, Medium power, 20-50kV, 10-100kW

Klystron, High power RF, 50-150kV, 1-150MW
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http://cas.web.cern.ch/CAS/Denmark-2010/Lectures/ebeltoft-lectures.html

In a synchrotron, the beam energy is proportional to the magnetic field (B.=p/e).

The magnetic field is generated by the current circulating in the magnet coils.

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Magnet
current
Magnetic field
in the air gap
LHC vistar : Beam Energy = Dipole Current
The dipole magnets shall have a high field homogeneity which means a high current
stability. The good field region is defined typically within 10
-4
B/B.

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The relation between the current and B-field isnt linear due to magnetic hysteresis and
eddy currents.

In reality, Beam Energy = kbDipole field kiDipole current

Classical iron yoke

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Magnet current
Magnet field
For superconducting magnets, the field errors (due to eddy currents) can have dynamic
effects.

13
Decay is characterised by a significant drift of
the multipole errors when the current in a
magnet is held constant, for example during
the injection plateau. When the current in a
magnet is increased again (for example, at the
start of the energy ramp), the multipole errors
bounce back ("snap back") to their pre-decay
level following an increase of the operating
current by approximately 20 A.
For the energy ramp such as described in [3],
the snapback takes 50-80 seconds but this can
vary if, for example, the rate of change of
current in the magnet is changed.
http://accelconf.web.cern.ch/accelconf/e00/PAPERS/MOP7B03.pdf
Decay Snapback
Measuring the magnetic field is very difficult and needs a magnet outside the tunnel.

In most of the synchrotrons, all the magnets (dipole, quadrupole, sextupole, orbit
correctors,) are current control.

The beam energy is controlled by the current of the dipole magnet.

To operate a synchrotron, operator needs to measure the beam position with pick-up.

From control room:
Is my accelerator an Ampere meter ?

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Now, you know that accelerators need high precision power converters.

What are the main parameters you should define with

accelerator physicists
&
magnet designers?

Dont let the accelerator physicists work alone with the magnet designers.

Powering optimization plays with magnet parameters

The power engineers have to be included in the accelerator design from the beginning!

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Magnet parameters
Magnet parameters seen by the power converters:
- Inductance, in mH
- Resistance, in m
- Current limits
- Voltage limits (insulation class)
- di/dt limits

much better, magnet model including saturation effect.

Even better, magnet model between Bfield and current.

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Rs Rm
Rp
L
Load model 3
Inductance
Current
L
L
sat

I
sat_start
I
sat_end

L
m
(I)=f(I).L
Load Saturation model
Circuit layout
The magnets can be powered individually or in series.

Individually:
- increase flexibility of beam optic
- B-field can be different depending of the cycles (hysteresis)
- Global cost is higher, more DC cables, more power converters
- Needed when the voltage goes too high (>10kV magnet class)
- Needed when the energy stored is too big (superconducting magnets)

Series connected:
- B-field identical
- Rigid optic. Need trim power converters to act locally.
- Global cost reduced, less DC cables, less power converters but bigger in power rating.

-
17

To get the same B-field in all the magnets, the
classical solution is to put all the magnets in series.

Generally done with dipole, quadrupole and
sextupole.

Example of SPS quadrupole

Lead to high power system for Dipole and quadrupole
powering.

Return cable must be put in opposite direction to the
magnet to avoid making loop.

Or power all the upper coils in one way, and back
with the lower coils.

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Circuit layout
But when the power becomes too high, the circuit needs to be split.
First time with LHC in 8 sectors.

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Circuit layout
Powering Sector:

154 dipole magnets
total length of 2.9 km
Tracking between sector !
For synchrotron source lights, the quadrupole are generally individually powered to
adjust the beam size (beta function) for each users (corresponding to a Fodo cell).
Example, SESAME cell.

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Circuit layout
Nested circuits
Nested powering scheme is popular with accelerator physicists and magnet designers.

Allows association of different magnets or to correct local deviation over a long series
of magnets.
Main reasons: saving on DC cables, current leads, lower power converter rating,

Example, LHC inner triplet

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RQTX2 5kA 8V
RQX 7kA 8V
RQTX1 600A 10V
FWT 7 kA
HCRYYAA
FERMILAB
MQXB
Ultimate current : 12290 A
Inductance : 18.5 mH
Stored Energy at nomimal
current : 1200 kJ
KEK
MQXA
Stored Energy at nominal
current : 1890 kJ
KEK
MQXA
Stored Energy at nominal
current : 1890 kJ
Free Wheel
Diode
Circuits are coupled!
control issues!
Circuit optimization
The powering optimization plays with the magnet parameters, the power converter
parameters and the circuit layout.

For the same integral field, the magnet can be done in different ways.
The magnet parameters are:
- Number of turns per coil N
- Maximum current I
- Current density in the conductor J
- Length/field strength of the magnet

Advantages of large N
- Lower I
- Lower losses in DC cables
- Better efficiency of power converter
Drawbacks of large N
- Higher voltage
- Magnet size (coil are bigger due to insulation)

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Circuit optimization
Advantages of lower J
- Lower losses in magnet
- Less heat to dissipate in air or water

Drawbacks
- Higher capital cost
- Larger magnets

Global optimization shall be done including capital investment, cooling system and energy
consumption.

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Water cooled magnet
Air cooled magnet
DC magnet
DC magnets have a solid yoke which prevents to pulse it. They are used
for economical raisons in experimental areas or transfer lines.

Their eddy currents need a long decay time to disappear (tens of second
to minutes). The yoke represents ~50% of the magnet cost.

If the beam isn't present all the time, then big saving can be achieved by
pulsing the magnets. The energy consumption is proportional to beam duty
cycle.

DC magnet advantages
- Cheaper magnets
- Simple powering scheme

DC magnet Drawback
- High energy consumption

One example of study for EAST Area at CERN, where a energy reduction
of 90% could be achieved. https://edms.cern.ch/document/1255278/1

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t (s)
B (T),
I (A)
Beam passage
Magnet grounding
For safety reasons, the magnet shall be isolated from the mains. The power converter
needs an insolation transformer in its topology.

The magnets shall be connected to the ground somewhere, they cant be left floating
with parasitic capacitances.

One polarity can be connected directly to the ground, or via a divider for a better
voltage sharing.

The ground current shall be monitor.
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Magnet protection
The magnets shall have its own interlock system.
For warm magnets, it is quite simple (water flow, thermostat, red button,).
For superconducting magnets, it is quite complex (quench protection).

This interlock system shall request a power abort to the power converter.

Be careful, magnets are inductive load, the circuit cant be opened !
The power converter shall assure a freewheeling path to the current.

It can be inside the power converter for warn magnet,
or outside for superconducting magnet.
Easy Complex

26
ripples
27
Power converter
Load
H(s)
V = R . I + L . dI/dt
=> H(s) = 1/ (L/R . s + 1)
Voltage ripple is generated by the power converter

Current ripple is defined by load transfer function (cables & magnet)

B-Field ripple is depends on magnet transfer function (vacuum chamber,)

V I
Control
Magnet
F(s)
Current ripple
Depends of the load
The acceptable current ripple has to be fixed by the accelerator physicists.
In fact, it is the maximum B-field ripple which needs to be determined.
From the B-field ripple, we can determine the current ripple and then, fix the voltage ripple.
Voltage ripple specification
28
The voltage ripple has to be specified for all frequencies.

<50Hz: for regulation performance
50-1200Hz: for grid disturbance
1-150kHz: for power converter switching frequency
>150kHz: for EMC

Magnet cycle
The way that the magnets will be operated has to be defined from the beginning.

- Type of control: Current / B-field
- Maximum minimum current
- Complete cycle
- Injection current
- Maximum dI/dt, ramp-up
- Maximum flat top current
- Maximum dI/dt, ramp-down
- Return current
- Cycle time
- Degauss cycle / pre-cycle
- Standby mode

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Magnet cycle
30
Imagnet
Vmagnet
1
Imagnet
Vmagnet
1
2
Imagnet
Vmagnet
1
2
4
3 In quadrant 2 and 4, the magnet stored energy is returning to
the power converter.
E
magnet
= 0.5 * L
magnet
* I
2
Magnet current operation Power converter type
Power converter performance
The performance of the power converters have to be defined with the accelerator
physicists at the beginning of the project.

The term of precision is only a generic term covering accuracy, reproducibility and
stability.

The requirements depend on the magnet type and function. The most demanding are the
dipole and quadrupole magnets.

The tracking error is the ability of the power converter to follow the reference function.
- The static part is covered by the static performance (accuracy and reproducibility)
- The dynamic part comes from timing error and lagging error of the regulation.

All these requirements lead to the definition of the power converter controller.

31
I
measured

Iref
Digital Current loop
Voltage loop
V
I
B
Vref
e
V

G(s)
e
I

+
Reg.
F(s)
-
DAC
Power Converter control
32
Which current transducers can we use?
33
High-precision definition
34
Accuracy
The closeness of agreement between a test result
and the accepted reference value. (ISO)

Reproducibility
Uncertainty when returning to a set of previous
working values from cycle to cycle of the machine.

Stability
Maximum deviation over a period with no changes in
operating conditions.

Injection instance
ripple
Short-term
Overall precision
Pulse-to-pulse
Reproducibility
I
time
Injection instance
Trueness
Nee calibration to reference
Power converter resolution
35
The resolution is expressed in ppm of maximum DCCT current.
Resolution is directly linked to A/D system.
Smallest increment that can be induced or discerned.
ADC
DAC
I
meas
+ DI
.

V
I
B
I*
ref
DI*
ref

I*
meas.
DI*
Current regulation
36
The performance of the current regulation is critical for the machine. It can be a
nightmare for operators if the current doesnt follow the reference!

The controller has to manage the tracking error as well as the regulation.

Iref
Current reference
Imeas
Current measurement
0
20
40
60
80
0 1 2 3 4 5 6 7 8
0
1
2
3
4
C
u
r
r
e
n
t

o
f
f
s
e
t

i
n

M
i
l
l
i
a
m
p
s

C
u
r
r
e
n
t

o
f
f
s
e
t

i
n

p
p
m

o
f

2
0

k
A

Time in Seconds
I
0
= 1019.9 Amps
Reference
Measured
Power converter control
37
The converter control system is the interface with the operators.

It manages the timing system, the communication,
the state machine, the regulation.

With particles accelerators, the main difficulty is the need of synchronisation for all
equipment to control which prevents using directly standard commercial solution.

Acceptable synchronization jitter for power converters ~ 1-100s
It depends of the cycle time.
LHC cycle = 20, acceptable jitter 100s, sampling at 1ms
Power converter availability
38
The power converters are a key player in machine availability.

Their MTBF is generally on the order of 100000H.

With 1700 power converters in the LHC, a power converter is down every 3 days in
average.

Improving the MTBF is quite difficult, be careful with thermal design.

How can we improve the situation? Work on the MTTR

Redundancy, n+1

Hot spare, 1 and 1
Why the magnet power converters are so special?
The magnet power converters are high precision current control.

To build it, the technical solutions are outside the industrial standard:

- Need very low ripple
- Need current and voltage control over large range
- Operate in 1-2-4 quadrant

- Need high precision measurement
- Need high performance electronics
- Need sophisticated control and algorithm

Powering a magnet isnt classical. It is always custom power supplies

A power converter functional specification shall be written before starting the
power converter design.

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Special topologies
Special electronics and control
What shall contain the functional specification?
Short description of the machine
Description of the loads
- Magnet layout
- Magnet parameters
- Optimization with integral cost and energy saving
Description of the operation duty cycle
- Machine cycles
- Minimum and maximum beam energy
- Power converter rating
- Current precision
- Current tracking
- Control system
- Energy management
- Lock-out and safety procedure
- Infrastructure (layout, Electricity, Cooling, handling)
Purchasing and development strategy
Planning
Budget
Resource

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Power converter time scale
From power converter functional specification

Power converter design

simulation

Component design

3D mechanical integration

Production

Laboratory Tests

On site commissioning
41
Minimum 18 months
up to 3 years when
special development
is needed.
2
1 1
3 3
1
4
5 5 5 5
https://edms.cern.ch/document/829344/3
0 0.5 1 1.5 2 2.5
-500
0
500
1000
1500
2000
2500
Time[s]
Charger converter
Current in winding 0
0.1 0.101 0.102 0.103 0.104
50
100
150
200
250
300
Time[s]
0.85 0.851 0.852 0.853 0.854 0.855
1850
1900
1950
2000
2050
2100
Time [s]
1.69 1.691 1.692 1.693 1.694 1.695
0
50
100
150
200
250
Time[s]
Power converter purchasing
From power converter functional specification

Power converter technical specification

Call for tender

Award of contract

Design report

Prototype acceptance

Series production

On site commissioning
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Minimum 12 months
Minimum 6 months
https://edms.cern.ch/document/1292325

The design of power converters covers a large range of disciplines.
Need more than one specialist to built it, team work !

Power part:
- Power converter topology
- Semiconductors, switching frequency, thermal design, fatigue while cycling,
- Filtering
- EMC
- Connection to AC grid
- Energy management
- Protection and safety
Control part:
- Accuracy class
- Digitalisation
- Control loops
- Timing & synchronisation
- Control interfaces
- Interlocks
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In this first talk, I tried to make a list of questions that you can face when making a
particles accelerator.
You should find a lot of information to help you with the design of power converters and
associated control during the next week.
Summary

The magnet power converters are driving the beam.

Their performance are very challenging for particles accelerators.

A functional specification will help to clarify the requirements with the
accelerator physicists, magnet designers, project manager.
Energy is a major concern for society. Powering optimization is mandatory.

Particles accelerators need all your
creativity in many technical fields!

45
WikipediA
The Free Encyclopedia
Summary

At this stage, you should still have a lot of questions.

You will find in the next talks everything regarding power electronics and control.

I will come back at the end of the school with examples to illustrate
how we can do the right thing.

Enjoy your CAS!
46

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CERN Accelerator School

Power converter requirements

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